Method of manufacturing cigars with reinforced heads



24, 1966 T KAUFMANN 3,252,465

METHOD OF MANUFACTURING CIGARS WITH REINFORCED HEADS Original Filed July17, 1958 16 ""IIIIIIH DIRECTION OF ROLLING INVENTOR. THEODORE KAUFMANNT15 2 BY AGENT 3,252,465 METHDD OF MANUFACTURING CIGARS WlTI-IREINFORCED HEADS Theodore Kaufmann, Brookville, N.Y., assignor toGeneral Cigar Co., Inc., New York, N.Y., a corporation of New YorkOriginal application July 17, 1958, Ser. No. 749,210, new Patent No.3,067,753, dated Dec. 11, 1962. Divided and this application Aug. 23,1962, Ser. No. 218,891 4 Claims. (Cl. 1331-20) This application is adivision of copending application Serial No. 749,210, file-d July 17,1958, now US. Patent No. 3,067,753, granted December 11, 1962.

This invent-ion relates to a method of manufacturing a cigar having animproved reinforced head.

As is well known in the art, cigars manufactured according to moderntechniques are composed of short or long cut filler tobacco, rolled inan inner binder to form a bunch which in turn is rolled in an externalwrapper to form the finished cigar. While both the binder and wrapperhave long been out directly from leaf tobacco, the newer practice is touse as the binder tobacco in sheet form prepared from finely dividedtobacco and an adhesive or film-forming agent.

A long standing problem of cigar manufacturers is the United StatesPatent frequent disintegration of the head of the cigar while it isbeing smoked due to the damage caused to the wrapper and binder as aresult of excessive chewing and other manipulation of the cigar head inthe smokers mouth. The taste, feel and sight of a disintegrated orpartially disintegrated head of a cigar lead to an unfavorable attitudeby many people toward cigar smoking. Thus, this problem reduces cigarsales.

Various proposals have been made for minimizing or eliminating theproblem of head disintegration in the smoking of cigars. For example,one proposal involves the use of a mouthpiece composed of a foreignmaterial at the head of the cigar either exposed or covered by thewrapper. There are several disadvantages connected with this scheme.From the smokers point of view, the foreign material of the mouthpiecewhich usually extends through most of the cross-section of the cigaracts to absorb many of the aromatic components of the cigar smokethereby detracting from the smoking quality of the cigar. In addition,the cigar tends to break between the inner border of the mouthpiece andthe rest of the cigar while it is being smoked due to the tensionexerted against the wrapper and binder as the cigar is being manipulatedin the smokers mouth. A disadvantage in the use of a mouthpiece from themanufacturers point of View is connected with the fact that thecigarhunch is prepared by helically rolling a binder around a certain amountof filler tobacco .and the existing complex machines for making cigarscannot be operated to include a mouthpiece within the bunch. It wouldalso be difiicult to change the current mass production technique ofrolling a wrapper around the bunch to come out with a cigar in which thebunch and mouthpiece are separately enclosed within the wrapper.

Another common proposal for preventing the disintegration of the head ofa cigar While it is being smoked is to Wrap or coat the outside of thecigar head with protective material, e.g., cellulose nitrate or acetate,regenerated cellulose, paper, cork, etc. While such an external shieldmay be effective in preventing disintegration of the cigar 'head in asmokers mouth, the feel and taste (including lack of taste) of amaterial other than tobacco are offensive to many cigar smokers.Moreover, the application of ice the wrapper is rolled on the bunch fromabove by means of a wrapper transfer arm which has a complicated motionand accomplishes the step of rolling the broad portion of the wrapper onthe body of the bunch by means of one type of helix and the flag portionof the wrapper on the head of the bunch with a tighter helix, i.e., ahelix having a smaller and decreasing pitch. Since the externalprotective material cannot be applied with the wrapper in the existingcigar-making machines, it would be necessary to apply the protectivematerial by a separate procedure which would obviously increase the costof cigar manufacture.

It is an object of this invention to provide a simple and effectivemethod of reinforcing the head of a cigar which is filled with fillertobacco and has a tobacco wrap-- per on its outside as in conventionalcigars, so that no aromatic components of the smoke are filtered out andthe mouth of the smoker comes in contact with tobacco rather'than anyforeign material.

This object is achieved with commonly available cigarmaking machines byrolling the filler tobacco in a binder laid on the surface of a rollingapron of such a machine together with an insert strip of a reinforcingsheet, most of one face of the strip being in contact with a face of thebinder. While the binder is placed on the rolling apron in the usualposition So that it may be helically rolled around the filler tobacco toform the bunch, the insert strip, which in most cases is rectangular, isplaced below the binder on the rolling apron so that it lies across thehead end of the binder with the larger dimension of the strip extendingsubstantially parallel to the direction of rolling. The larger dimensionof the insert strip is at least 0.5 inch longer than the circumferenceof the bunch so that the ends of the strip overlap one another at least0.5 inch. When the filler tobacco is rolled in the hinder, the insertstrip is simultaneously Wound spirally, in a plane transverse to thecigar axis, (not helically along the length of the bunch) at the headend of the resultant bunch. Since the reinforcing strip is longer thanthe circumference of the bunchand this strip is rolled around the fillertobacco while the major portion of one face of the strip is in contactwith a face of the binder, at least a minor portion of the other face ofthe strip is in contact with the other face of the binder. In otherwords, one end of the, insert strip is interleaved with the rolled upbinder and, therefore, the strip is held in place in the bunch by thebinder.

The insert strip of the finished cigar will be inside the wrapper sothat the cigar has the usual appearance and only tobacco comes intocontact with a smokers mouth. In addition, as is obvious from theconstruction of a cigar made according to this invention, the path ofthe smoke from the lighted tuck end, through the cigar to the smokersmouth, is substantially the same as in a conventional cigar so thatwhile the head of the cigar is strengthened considerably againstdisintegration, there is still no filtering out of any of the aromaticcomponents of the smoke.

In view of the fact that the insert strip is Wound around the fillertobacco integrally with the binder in preparing the bunch which is thenfurther enclosed in the wrapper, it is obvious that the reinforced headof a cigar manufactured according to this invention is strong andsecure. When the insert strip is placed on the rolling apron under thebinder, it is advisable to use a dab of innocuous adhesive on the faceof the strip which is to be contiguous with the binder and at the end ofthe strip which will be the inner end of the spiralled strip in thebunch. This is done not for the purpose of keeping the insert strip inplace in the finished cigar or even in the bunch but to ensure that theend of the strip which is rolled up first will follow the binder duringthe rolling operation. In addi- 9 tion, when the insert strip is belowthe binder on the rolling apron, a dab of paste is also applied to theupper face and at the opposite end of the strip to hold down the outerend of the spiralled strip in the bunch.

In addition to the inherent advantages in the finished cigar, thereinforcement of a cigar head according to this invention may be carriedout much more easily than other methods of reinforcement. This can bebest appreciated when the conventional means of mass producing cigars isconsidered. In preparing the bunch, the binder is placed horizontally onthe rolling apron and is held flush against the apron by a partialvacuum applied through small openings or perforations in the apron froma chamber beneath it. The binder is cut in a shape adapted to be formedinto a tubular element by a relatively simple rolling action executed bythe rolling apron. To obtain the advantages of this invention, it ismerely necessary that the insert strip be placed on the rolling apronbelow the binder with its larger dimension substantially parallel to thedirection of roll and near the head end of the binder so that when thetiller tobacco is dispensed and the bunch rolled the insert strip willbe integrally rolled with the binder. This is easily carried out in themass production of cigars by means of an applicator mechanism which cutsan insert strip of the desired size from a roll of the reinforcing sheetand places it in the desired position on the rolling apron relative tothe binder before the hunch is rolled. This is considerably simpler thanmanufacturing cigars with separate mouthpieces which involves anentirely distinct operation, or applying reinforcing strip either withor after the rolling of the wrapper. It would be diflicult to apply areinforcing strip with the wrapper in view of the fact that the wrapperis rolled on the bunch from above by means of a complicated motion ofthe wrapper transfer arm which provides for the broad part of thewrapper to be wound around the bunch in one type of helix and the flagportion of the wrapper to be wound around the head of the bunch with atighter helix, i.e., one having a smaller and even diminishing pitch.

The insert strip may be cut from any of various types of reinforcingsheets suitable for the desired purpose, e.g., tobacco sheets, paper,cork, regenerated cellulose, plastic films, etc. While the insert stripis of a width that it rarely covers more than 1.5 inches of cigar lengthat its head, smokers occasionally smoke cigars down to very short stumpswith the result that the burning zone of the cigar reaches the insertstrip. For this reason, it is preferred to use a strip of a strongtobacco sheet which on burning will not yield an obnoxious smoke odorand taste. Such a tobacco sheet may be made in accordance with theteachings of U.S. Patent 2,797,689, granted July 2, 1957, to W. G.Frankenburg.

The reinforced head of this invention may be applied to any type ofcigar which has the three basic parts of filler, binder and wrapper.However, it is particularly advantageous when the binder is cut from atobacco sheet prepared from finely divided tobacco and a water-solubleadhesive, e.g., methyl cellulose as disclosed in U.S. Patent 2,592,553,granted April 15, 1952, to W. G. Frankenburg and P. W. Garbo.

The selection of the reinforcing sheet is based on such factors asthickness, flexibility and strength both when dry and when moistened bychewing in the smokers mouth. Suitable reinforcing sheets are generallynot more than 0.005 inch, preferably not more than 0.003 inch, inthickness; the flexibility of such sheets should be sufficient to permitthe insert strip to be readily spiralled at the head end of the bunchwithout causing objectionable bulging or distortion of that end of thebunch. Also, the insert strip should have enough flexibility that asmoker who chews the head of a cigar while smoking will not notice anyunusual hardness in the reinforced head.

To further define the invention, reference will now be made to theaccompanying drawings, FIGURE 1 of which shows the positions of thebinder and insert strip on the rolling apron with the insert stripplaced under the binder, and FIGURE 2 of which shows the rolling of thewrapper around the cigar bunch with the reinforced head.

FIGURE 1 shows the portion of rolling apron 10 of a cigar-making machinewhich has a multiplicity of perforations 11 for holding down in a smoothcondition binder 12 laid thereon. Insert strip 13 is deposited on apron10 before binder 12. Strip 13 may be cut from a roll of a reinforcingsheet and placed on apron 10 by a dispensing mechanism of the type shownin pending U.S. application Serial No. 303,210, now U.S. Patent3,060,775, granted October 30, 1962, while binder 12 may be cut from aroll of a tobacco sheet and laid on apron 10 over strip 13 by p adispensing mechanism of the type shown in U.S. Patent 2,846,010, grantedAugust 5, 1958. The direction of rolling followed by apron 10 inexecuting the rolling of the cigar bunch is indicated by arrow 14. Itwill be noted that the longer dimension of strip 13 is essentiallyparallel to the direction of rolling. After a charge of filler tobaccohas been rolled up in binder 12 to form the bunch, the bunch goes to acrimper which shapes the ends of the bunch and cuts off the marginalportions of binder 12 at the bunch ends. Dotted lines 15 and 16 indicatethe lines along which the marginal portions of binder 12 are cut off atthe crimper. It will be noted that strip 13 is generally positioned onapron 10 so that outer longer edge 17 thereof is a small fraction of aninch, say to A; inch, inwardly away from crimper cutting line 15 ofbinder 12. By so positioning strip 13 relative to crimper cutting line15 of binder 12, there is no possibility of disturbing the spiralledstrip 13 in the cigar bunch while the ends are being trimmed in thecrimper. T 0 ensure that leading end 18 of strip 13 will follow binder12 while it is being rolled up by apron 10, it is advisable to place adab of paste or adhesive 19 between binder 12 and end 18 of strip 13.Similarly, it is advisable to apply a line of paste 20 along thetrailing end 21 of strip 13 so that end 21 is sealed to the completedbunch and unravelling of strip 13 before the wrapper is wound around thebunch is prevented.

FIGURE 2 shows binder 12 and strip 13 after being rolled to form thecigar bunch. The spiralled strip 13 with its trailing end 21 sealed bypaste line 20 is positioned at the head of the bunch adjacent crimpercutting line 15 of binder 12. Viewed from the right end of the bunch inFIGURE 2, wrapper 22 is shown being rolled around the bunch by thecounterclockwise rotation of the bunch, this rotation being indicated bythe arrow at the left end of FIGURE 2.

Various sizes and shapes of binder and insert strips are possible. Theends of the spiralled insert strip should be overlapped at least 0.5inch but there is little or no justification for using such a length ofstrip that when spiralled in the bunch there will be two or more fulllayers of the reinforcing sheet in the cigar head.

What is claimed is:

1. In the method of manufacturing cigars wherein a binder is placed onthe rolling apron of a cigar-making machine and rolled around a mass offiller tobacco to form a bunch around which a wrapper is then rolled,the improvement which comprises placing a narrow strip of a reinforcingsheet in a predetermined position on said rolling apron with said binderlaid over said strip, and rolling by the operation of said rolling apronthe so placed strip simultaneously with said binder around said mass offiller tobacco to form said bunch, said predetermined position beingsuch that said strip is placed with its outer longer edge essentiallyparallel to the direction of rolling and with a clearance of a smallfraction of an inch inwardly away from the crimper cutting line of saidbinder whereby said strip is spiralled at the head end only of saidbunch by the simultaneous rolling of said strip and said binder and is.not disturbed while the ends of said unch are b ing ttrimmed in thecrimper.

2. The method of claim 1 wherein dabs of adhesive are applied on theends of said strip on the face over which said binder is laid.

3. The method of manufacturing an improved cigar which comprises placinga narrow strip of a reinforcing sheet in a predetermined position on therolling apron of a cigar-making machine, laying a binder over said stripso that the end portion of said strip away from the start of rollingprojects beyond said binder, said predetermined position being such thatsaid strip is placed with its outer longer edge essentially parallel tothe direction of rolling and with a clearance of a small fraction of aninch inwardly away from the crimper cutting line of said binder, rollingsaid binder and said strip simultaneously around a mass of fillertobacco by the operation of said rolling apron thereby forming a bunchwith said strip spiralled at the head end only of said bunch, said stripspiralled at the head end being not disturbed while the ends of saidbunch are being trimmed in the crimper, and rolling a wrapper aroundsaid bunch to yield said improved cigar. 20

4. The method of claim 3 wherein dabs of adhesive are applied on saidend portion and the opposite end portion of said strip on the face overwhich said binder is laid.

References Cited by the Examiner UNITED STATES PATENTS 867,825 10/1907Moesinger 13136 1,645,012 10/1927 Kitchel et a1. 13136 X 1,969,8348/1934 Berriman -1 13l11 2,178,820 11/1939 Todoroif 131-15 2,914,07111/1959 Straus 13111 FOREIGN PATENTS 742,561 12/ 1943 Germany. 514,66411/ 1939 Great Britain.

SAMUEL KOREN, Primary Examiner.

ABRAHAM G. STONE, Examiner.

1. IN THE METHOD OF MANUFACTURING CIGARS WHEREIN A BINDER IS PLACED ONTHE ROLLING APRON OF A CIGAR-MAKING MACHINE AND ROLLED AROUND A MASS OFFILLER TOBACCO TO FORM A BUNCH AROUND WHICH A WRAPPER IS THEN ROLLED,THE IMPROVEMENT WHICH COMPRISED PLACING A NARROW STRIP OF A REINFORCINGSHEET IN A PREDETERMINED POSITION ON SAID ROLLING APRON WITH SAID BINDERLAID OVER SAID STRIP, AND ROLLING BY THE OPERATION OF SAID ROLLING APRONTHE SO PLACED STRIP SIMULTANEOUSLY WITH SIAD BINDER AROUND SAID MASS OFFILTER TOBACCO TO FORM SAID BUNCH, SAID PREDETERMINED POSITION BEINGSUCH THAT STRIP IS PLACED WITH IT OUTER LONGER EDGE ESSENTIALLY PARALLELTO THE DIRECTION OF ROLLING AND WITH A CLEARANCE OF A SMALL FRACTION OFAN INCH INWARDLY AWAY FROM THE CRIMPER CUTTING LINE OF SAID BINDERWHEREBY SAID STRIP IS SPIRALLED AT THE HEAD END ONLY OF SAID BUNCH BYTHE SIMULTANEOUS ROLLING OF SAID STRIP AND SAID BINDER AND IS NOTDISTRUBED WHILE THE ENDS OF SAID BUNCH ARE BEING TRIMMED IN THE CRIMPER.